'the Betty'

[level]

Hi all,

Starting up a new project. Its a 1990 GS500. Received in in running, but non-licensable condition. Planning on doing a mild frame up build. Just going to focus on sorting out all the minor issues and making it look nice.

I do not know much about the GS line so I'll be looking to the community for all sorts of help.

Here is the current state of things...

-The tires are pretty dry and are cracking a little.
-The front wheel has a dent on both sides of the rim.
-The wiring harness is a total loss, its been hacked pretty good.
-The engine is leaking oil from the base of the cylinder bore.

[kyle1]

and the tank is beyond ugly and slightly rusty on the inside

[adidasguy]

Replace the front rim. Someone hit a hard curb.
Wiring: Old harnesses are usually pretty bad. They can be found. 89-00 are basically the same except for the clutch switch connector. Consider upgrading all to the newer wiring. My preference is 2006+.
Wiring is 2001-2002, then 2004-4005, then 2006+
Which ever year you decide on, the right hand controls changed connectors. The left hand controls are all the same.
I'm doing various rebuilds and will be upgrading the wiring. I suppose I could sell you the older wiring harness from a bike if it is in good condition. I'm the wiring expert so ask questions.

[level]

Alright, well it looks like I've come to the right place!

A new rim has already been acquired, nice and straight.

The wiring is what started this whole debacle. It was pretty mangled and I began to try and figure it out, which led from one thing to another. So now its a whole frame up project. The tail section was also cut off by the previous owner leaving it pretty ugly and out of place. So I want to clean it up a little and put a clean looking tail fairing on it.

I have lots of wiring questions but I will have to get my harness laid out so I can figure out where I was at. I want to make a nice, clean custom harness that I can hide as best as I can.

[adidasguy]

No need to make a harness.
2004+ ones are often $10 +postage.
They hide. Nothing is seen.
As mentioned, go 2006+

I got the wiring harness, coils, stator, pickups, CDI, regulator and all relays for a 2006 for $115. It is for an upcoming project or will require an older bike if need be.
Deals are there.

[yamahonkawazuki]

No need to make a harness.
2004+ ones are often $10 +postage.
They hide. Nothing is seen.
As mentioned, go 2006+

I got the wiring harness, coils, stator, pickups, CDI, regulator and all relays for a 2006 for $115. It is for an upcoming project or will require an older bike if need be.
Deals are there.

adidas here is our resident go to guy for parts. the base gasket leak, can try breaking the torque on hte beadbolts, then torquing to spec. ( and clean off oil) see if oil leak returns, tbh if its not massive, maybe 1/4 qt over 2000 miles id leave it be. if shes a massive leaker, remove head, then cylinders. but if digging in that deep also look @ cost of a donor engine, and keep that one for spare parts

[Funderb]

oil leak could also be the little copper crush washers that go under the head bolts.

I think thats what happened to tombstone when he neglected to replace them on rebuild.

[level]

Alright, I'll try re-torquing the head bolts. Anyone know the spec on them? And the tightening order? I suppose I should do a search, lol.

Ok, I'll ponder the harness and I may end up buying a complete one. The bike has no speedometer, no tach, no signals or any sort, so... that's kind of what I'm working with. The direction I'm taking this bike is not a nice, neat finished product. Its main goal is just to be a simple, weekend rider.

But I'll take everything into consideration as it happens.

[adidasguy]

You gots non of dem der manuals?
They all have the torque specs.

[level]

No, not yet. I suppose I should hop on ebay and acquire one.

[adidasguy]

http://www.amazon.com/Suzuki-1989-2008-Haynes-Service-Repair/dp/1844258815/ref=sr_1_1?ie=UTF8&qid=1347307686&sr=8-1&keywords=gs500+haynes

[level]

Danke

[catch2otwo]

I have the factory service manual as well.  pm me with your email and ill email you a copy.